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XDI Manual Version 1.8

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2017 Electromotive, Inc.

5.2.b “3000” Knob ....................................................................................................................................... 24

5.2.c “8000” Knob ....................................................................................................................................... 24

5.3 Measuring Timing ................................................................................................................................... 25

5.4 External Advance Control....................................................................................................................... 26

5.4.1 Vacuum Advance (a.k.a. Boost Retard)............................................................................................... 26

5.5 External Retard Control .......................................................................................................................... 26

5.5.a Backup Sensor ..................................................................................................................................... 27

5.6 Tachometer Output ................................................................................................................................. 27

5.7 Primary and Auxiliary Rev Limiter ........................................................................................................ 28

6.0 Diagnostics ....................................................................................................... 29

Appendix A ............................................................................................................ 29

Appendix B ............................................................................................................ 31

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Summary of Contents for xdi

Page 1: ...Product Installation Manual User s Guide V1 8 Electromotive Inc 703 331 0100 9131 Centreville Road 703 331 0161 fax Manassas VA 20110 support electromotive com ...

Page 2: ...nfiguration Settings 9 3 0 Hardware Installation 10 3 1 Pre Installation Checklist 10 3 2 Cautions and Warnings 10 3 3 Installing the Direct Fire Unit DFU 10 3 4 Installing the XDI 11 3 5 Trigger Wheel and Sensor Installation 12 3 5 a Crankshaft Trigger Installation for 60 2 Tooth Wheel 12 3 5 b Magnetic Crank Sensor Installation 13 4 0 Wiring 14 4 1 Introduction 14 4 2 Wiring the DFU s 16 4 2 a D...

Page 3: ... 8000 Knob 24 5 3 Measuring Timing 25 5 4 External Advance Control 26 5 4 1 Vacuum Advance a k a Boost Retard 26 5 5 External Retard Control 26 5 5 a Backup Sensor 27 5 6 Tachometer Output 27 5 7 Primary and Auxiliary Rev Limiter 28 6 0 Diagnostics 29 Appendix A 29 Appendix B 31 ...

Page 4: ...d Warranty Service Notify us at support electromotive inc com or 703 331 0100 M F 8 30 to 5 00 EST Then send 1 a completed Electromotive Diagnostic Repair Request Form with a summary of the issues you are experiencing 2 a copy of your sales receipt and 3 the XDi or TEC unit Ship to Electromotive Repairs 9131 Centreville Road Manassas VA 20110 You must include the sales receipt and it must clearly ...

Page 5: ...o repair or replacement of the defective product In no event will Electromotive be liable for any monetary damages whether direct indirect consequential special incidental punitive exemplary or other damages arising out of or in connection with any product including third party products sold or provided by Electromotive This exclusion applies to all monetary damages of any kind including but not l...

Page 6: ... your knob settings Setting the timing advance curve is a simple task that anyone can understand In addition to synchronizing and firing the plugs at the correct advance angle the XDI also computes the exact dwell to produce 9 amps of coil current Coil charging is measured dynamically so changes in RPM battery voltage or temperature are all accounted for on every spark This corrects any errors tha...

Page 7: ... can reduce the flow of electricity to the spark plug an ignition wire that reportedly generates an increase in spark energy will have no effect on the spark jumping across the spark plug gap since the energy consumed at the spark plug gap won t be any more than what is needed to jump the gap For a more obvious example of this a 25watt light bulb won t use any more energy or produce any more light...

Page 8: ...Boost 0 022 0 55mm Use of resistor plugs is highly recommended for optimum noise suppression If using anything other than a resistor spark plug wire a resistor plug MUST be used The bottom line is this the XDI system uses an inductive long duration charge at battery voltage charging method for the coils which is completely different than the capacitive short duration charge at higher than battery ...

Page 9: ...3 SW4 SW5 SW6 SW7 The UP position The DOWN position Figure 1 Picture of XDI with Cover Plate Removed Engine Configuration Tach SW1 SW2 SW3 SW4 SW5 SW6 SW7 SW8 1 Cylinder 1 Cyl UP UP UP DOWN DOWN DOWN DOWN DOWN 2 cylinder 4 stroke 1 Cyl UP UP UP DOWN DOWN DOWN DOWN DOWN 2 Cylinder 2 Stroke 4 Cyl DOWN DOWN UP DOWN DOWN DOWN DOWN DOWN 3 Cylinder 2 and 4 Stroke 6 Cyl UP DOWN DOWN DOWN DOWN DOWN DOWN D...

Page 10: ...o lead to fatal electrocution 2 Do not let the spark plug wires touch the block head frame or body The power of this ignition can burn through most spark plug wire insulation Use a quality 8mm or larger wire with two piece spring loaded contacts and wire separators 3 Replace spark plugs wires every year recommended 4 Remove any series ballast resistance in both the 12 volt power red and the ground...

Page 11: ...od location is in the kick panel of a vehicle originally equipped with a factory ECU If the XDI must be mounted in an area that is partially exposed to the elements there should not be a problem the circuit board is completely sealed for harsh environment installations Secure the controller with four socket head cap screws The wiring harness should be passed through the firewall using a suitable g...

Page 12: ...8 the thickness of the trigger wheel A variety of application specific trigger wheels are available Universal trigger wheels are also available in a variety of sizes To choose the proper size trigger wheel find the diameter of the pulley or damper on which the wheel is to be mounted The trigger wheel diameter should be at least larger than this diameter It should also be noted that the trigger whe...

Page 13: ...lse triggering of the ignition This is the reason for not mounting the trigger wheel to the outer ring of a harmonic damper As such any custom magnetic sensor bracket should be very rigid The sensor can be secured with either a setscrew or a clamping arrangement as long as the 1 2 sensor is utilized part number 250 72250 If the smaller 3 8 sensor is utilized a clamping arrangement should be employ...

Page 14: ...sonable amount of time If this is your first experience with the XDI it is strongly recommended that you read this entire manual Once you are familiar with the details contained in this manual simply use the Quick Reference Sheets provided in Appendix B NOTE Always disconnect the battery when doing ANY electrical work on a vehicle Use common sense when around electrical systems particularly the DF...

Page 15: ...pin connector See Table 5 for pin definitions Note the 2 conductor with shield cable is for the magnetic crank trigger sensor After you wire the vehicle the three wires already pinned should be inserted into connector C as described in Section 4 3 B DFU cable This cable connects the XDI to the DFU If you are using 2 DFU s you will need to request a second cable with the purchase of the XDI The pin...

Page 16: ...FU 2 Shield Bare 4 2 Wiring the DFU s 4 2 a DFU to XDI DFU s are made by Electromotive in two variants 2 coil and 3 coil Each coil drives two spark plugs in waste spark ignition setups Two cycle applications will not use waste spark The first step in wiring the DFU s is to install the ground wire The DFU s come from our factory with a ground wire pre installed on a tapped un anodized hole This wir...

Page 17: ...iguration The proper coil must be connected to the correct cylinder in the firing order 4 2 c Coil Notation The following notation is used when referring to coils A letter and a number are combined to identify a coil The letter refers to the coil location on the DFU The coil located closest to the connector is Coil A The coil next to it is Coil B If the DFU contains three coils the last coil is Co...

Page 18: ... coil is devoted to 1 spark plug on compression and 1 spark plug on exhaust at all times DO NOT run Coil A from one DFU to both spark plugs of cylinder 1 This would place the load of two spark plugs on compression to only one coil and a severe performance problem would result Engine 4 cylinder 2 stroke Note Single tower coils are used for this application see Figure 9 Firing Order 1 2 3 4 Coil Fir...

Page 19: ...his engine the firing order might be 1 6 5 4 3 2 Note the typical odd fire V6 is a 90o block with three connecting rod journals on the crankshaft These were used in NASCAR s Busch series a few years ago However the firing order does NOT correspond to the order of TDC events for the engine Without concern for whether the TDC events are compression or exhaust here is the order of TDC events for the ...

Page 20: ...Under full load the engines generally make best power with closer to zero degrees of split A rotary will run on just the leading or trailing ignition but a power loss will occur Keep this in mind when trying to diagnose ignition wiring problems Rotor 1 Leading Coil Channel A1 Trailing Coil Channel A2 Coil Channel A1 and A2 are split by the value in the Dual Plug Timing Split XDI 2 only Rotor 2 Lea...

Page 21: ...m it will not provide a good connection to ground If more than one DFU is used on a vehicle each one will require its own ground wire Additionally make sure that the coil screws are fully tightened at all times 4 3 Crank Sensor The crank sensor uses the two conductor with shield cable that is inserted into pins 3 10 and 11 of the 23 pin connector on the XDI The pins for the sensor side of the harn...

Page 22: ...Yellow 10 18 2 DFU Power Red w white stripe 10 18 10 NOTE DFU Power shown is for one DFU If you are using two DFU s you must have two circuits capable of 10 amps NOTE 24 volt units are available upon special request The installation regarding power distribution depends on the user s preference and needs Figures 11 and 12 show the recommended installation Figure 11 Recommended power connections for...

Page 23: ...typically be low with too little timing More timing makes the combustion process occur sooner and will decrease exhaust temperature It also makes an engine idle smoother NOx emissions will rise with too much timing With increasing RPM the timing needs to be advanced for optimum power This is a result of the available time for combustion decreasing with increasing RPM The peak cylinder pressure nee...

Page 24: ...street stock engine 5 2 c 8000 Knob At 8000 RPM you can add or subtract up to 12 degrees of timing from the advance you selected at 3000 RPM This value is added or subtracted proportionately from 3000 RPM to its full amount at 8000 RPM Try 2 NOTE Due to variations in printing and assembly the knob dials may not exactly indicate the actual values Always use a timing light to verify your settings NO...

Page 25: ...ltmeter s positive probe in the ADV hole and place the negative probe in the GND hole on the XDI s cover plate Set your voltmeter to its lowest voltage setting The scenario shown in Figure 14 has the XDI advancing the timing 24 degrees BTDC The second place to measure the timing voltage is between the Advance Output wire pink pin 21 on the XDI and ground This allows the timing to be measured in th...

Page 26: ... response over the entire operating range and brings timing closer to optimum The Manifold Absolute Pressure MAP Sensor hooks up directly to the XDI s 5V GND and External Advance Control wire giving 15 of advance when the engine makes 30 of vacuum This advance is in addition to the knob selected timing At idle vacuum is high manifold pressure is low and the engine wants more advance since cylinder...

Page 27: ...ensor 5 teeth ahead advanced of the normal sensor a switch can be used to change crank trigger sensors and signal the Retard input to adjust the timing Figure 19 shows the location of the backup sensor The example shown is for clockwise configurations except 12 cylinder 5 6 Tachometer Output The tachometer output on pin 18 brown wire of the XDI is a 12 Volt square wave The tachometer output signal...

Page 28: ...f of a 120 Volt signal 5 7 Primary and Auxiliary Rev Limiter Most RPM limiters feel like hitting a brick wall The engine cuts off violently and recovers slowly The XDI s RPM limiter feels gentler and generates less sudden power changes in the engine reducing stress You may even hit the first or second stage without realizing it only noticing that the car stops accelerating and the engine feels sof...

Page 29: ...is not set using the dipswitches Refer to Section 2 1 for setting the configuration Problem When I crank the engine the status light stays solid green and the car will not start Possible Cause This problem is crank sensor related The XDI will flash red and green while the engine is starting If the status light does not flash the XDI does not see the trigger wheel The sensor could be bad Measure th...

Page 30: ...pliers to insert the pin s fully If you make a mistake you can extract the pin from the connector by pulling the wire You must make sure the red part of the connector is in the up or loose position Push the red part of the connector back into the connector when you are done Make sure the pins you inserted are all the way to the top of the connector If you need to push the pin further repeat the in...

Page 31: ...XDI Manual Version 1 8 Page 31 2017 Electromotive Inc Appendix B Quick Reference Sheets ...

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Page 33: ...XDI Manual Version 1 8 Page 33 2017 Electromotive Inc ...

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Page 36: ...XDI Manual Version 1 8 Page 36 2017 Electromotive Inc ...

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